Polyfluoroether based polymers

ABSTRACT

A composition which provides surface effects to substrates comprising a polymer containing at least one urea linkage prepared by
         (i) reacting (1) at least one organic diioscyanate, polyisocyanate, or mixture thereof, and (2) at least one fluorochemical compound of Formula I
 
R f —O(CF 2 CF 2 ) r (CH 2 CH 2 ) q (R 1 ) s XH  Formula (I)
    wherein
           R f  is a linear or branched C 1  to C 7  perfluoroalkyl optionally interrupted by one to three oxygen atoms,   r is 1 to 3, q is 1 to 3, s is 0 or 1,   X is O, S, or NR 2  wherein R 2  is H, or C 1  to C 6  alkyl, and   R 1  is a divalent radical selected from —S(CH 2 ) n —,   
               

     
       
         
         
             
             
         
       
         
         
           
             
               
                 p is 1 to 50, and R 3 , R 4  and R 5  are each independently H or C 1  to C 6  alkyl; 
               
             
             (ii) and then reacting with (3) water, a linking agent, or a mixture thereof.

This application Ser. No. 12/274,404 is a DIV of Ser. No. 11/598,333,filed Nov. 13, 2006 now U.S. Pat. No. 7,470,745.

FIELD OF THE INVENTION

This invention relates to the field of polyfluorinated compoundscontaining an ether linkage within the polyfluorinated chain, andparticularly to such polyurethane fluoropolymers useful to providesurface properties to substrates treated therewith.

BACKGROUND OF THE INVENTION

Various polymers made from perfluorinated compositions are known to beuseful as treating agents to provide surface effects to substrates.Surface effects include repellency to moisture, soil, and stains, andother effects, which are particularly useful for fibrous substrates andother substrates such as hard surfaces. Many such treating agents arefluorinated polymers or copolymers.

Most commercially available fluorinated polymers useful as treatingagents for imparting surface effects to substrates contain predominantlyeight or more carbons in the perfluoroalkyl chain to provide the desiredproperties. Honda et al, in Macromolecules, 2005, 38, 5699-5705 teachthat for perfluoroalkyl chains of greater than 8 carbons, orientation ofthe perfluoroalkyl groups, designated R_(f) groups, is maintained in aparallel configuration while for such chains having less than 6 carbons,reorientation occurs. This reorientation decreases surface propertiessuch as contact angle. Thus shorter chain perfluoroalkyls havetraditionally not been successful commercially for imparting surfaceeffects to substrates.

It is desired to improve particular surface effects and to increase thefluorine efficiency; i.e., boost the efficiency or performance oftreating agents so that lesser amounts of the expensive fluorinatedpolymer are required to achieve the same level of performance, or sothat better performance is achieved using the same level of fluorine. Itis desirable to reduce the chain length of the perfluoroalkyl groupsthereby reducing the amount of fluorine present, while still achievingthe same or superior surface effects.

U.S. Pat. No. 3,564,059 discloses perfluorinated ethers and polyethersuseful as plasticizers and solvents. No utility in providing repellencysurface effects to substrates is disclosed.

There is a need for polymer compositions which significantly improve therepellency and stain resistance of fluorinated polymer treating agentsfor fibrous substrates and hard surface substrates while using lowerlevels of fluorine. The present invention provides such compositions.

SUMMARY OF THE INVENTION

The present invention comprises a composition comprising a polymercontaining at least one urea linkage prepared by

(i) reacting (1) at least one organic diioscyanate, polyisocyanate, ormixture thereof, and (2) at least one fluorochemical compound of FormulaIR_(f)—O(CF₂CF₂)_(r)(CH₂CH₂)_(q)(R¹)_(s)XH  Formula Iwherein

R_(f) is a linear or branched C₁ to C₇ perfluoroalkyl optionallyinterrupted by one to three oxygen atoms,

r is 1 to 3, q is 1 to 3, s is 0 or 1,

X is O, S, or NR² wherein R² is H, or C₁ to C₆ alkyl, and

R¹ is the divalent radical —S(CH₂)_(n)—,

n is 2 to 4, p is 1 to 50, and R³, R⁴ and R⁵ are each independently H orC₁ to C₆ alkyl;

(ii) and then reacting with (3) water, a linking agent, or a mixturethereof.

The present invention further comprises a method of providing waterrepellency, oil repellency, stain release, hydrophilicity stain release,and cleanability to a substrate comprising contacting said substratewith the above polymer.

The present invention further comprises a method of providing soilresistance to a substrate comprising contacting said substrate with theabove polymer wherein the diisocyanate, polyisocyanate, or mixturethereof comprises one or more cyclic diisocyanates selected from thegroup consisting of 2,4-toluene diisocyanate; 2,6-toluene diisocyanate;diphenylmethane 4,4′-diisocyanate; diphenylmethane 2,4′-diisocyanate;3-isocyanatomethyl-3,4,4-trimethylcyclohexyl isocyanate; andbis-(4-isocyanatocylohexyl)methane and diisocyanate trimers of formula(IIa), (IIb):

The present invention further comprises a substrate to which has beenapplied the above polymer.

DETAILED DESCRIPTION OF THE INVENTION

Hereinafter trademarks are shown in upper case.

This invention provides polymers as described above, which are preparedfrom fluoroalcohols, fluorothiols, or fluoroamines containing aperfluoroalkyl ether. These compositions are useful for contributingstain-release, oil repellency, water repellency, hydrophilicity stainrelease, cleanability and soil resistance to fibrous and hardsubstrates, and for other uses where a perfluorinated end group providesspecial surface-modifying properties. The perfluoroalkyl group in thepolymers of the present invention contains 1 to 7 carbon atoms, andtypically exhibit surface properties equal to or greater thanconventional commercial surface treatment agents that typically containa perfluoroalkyl group having 8 to about 20 carbon atoms.

The fluoroalcohols used to make the compositions of the presentinvention are available by the following series of reactions:

The starting perfluoroalkyl ether iodides are made by the proceduredescribed in U.S. Pat. No. 5,481,028, herein incorporated by reference,in Example 8, which discloses the preparation of compounds of formula(V) from perfluoro-n-propyl vinyl ether.

In the second reaction above, a perfluoalkyl ether iodide (V) is reactedwith an excess of ethylene at an elevated temperature and pressure.While the addition of ethylene can be carried out thermally, the use ofa suitable catalyst is preferred. Preferably the catalyst is a peroxidecatalyst such as benzoyl peroxide, isobutyryl peroxide, propionylperoxide, or acetyl peroxide. More preferably the peroxide catalyst isbenzoyl peroxide. The temperature of the reaction is not limited, but atemperature in the range of 110° C. to 130° C. is preferred. Thereaction time varies with the catalyst and reaction conditions, but 24hours is typically adequate. The product can be purified by any meansthat separates unreacted starting material from the final product, butdistillation is preferred. Satisfactory yields up to 80% of theory havebeen obtained using about 2.7 mols of ethylene per mole of perfluoalkylether iodide, a temperature of 110° C. and autogenous pressure, areaction time of 24 hours, and purifying the product by distillation.

The perfluoroalkylether ethylene iodides (VI) are treated with oleum andhydrolyzed to provide the corresponding alcohols (VII) according toprocedures disclosed in WO 95/11877. Alternatively, theperfluoroalkylether ethyl iodides are treated with N-methyl formamidefollowed by ethyl alcohol/acid hydrolysis. A temperature of about 130°to 160° C. is preferred. The higher homologs (q=2, 3) of telomerethylene iodides (VI) are available with excess ethylene at highpressure.

The telomer ethylene iodides (VI) can be treated with a variety ofreagents to provide the corresponding thiols according to proceduresdescribed in J. Fluorine Chemistry, 104, 2 173-183 (2000). One exampleis the reaction of the telomer ethylene iodides (VI) with sodiumthioacetate, followed by hydrolysis.

The telomer ethylene iodides (VI) are treated withomega-mercapto-1-alkanols according the following scheme to providecompounds of formula (VIII):

The telomer ethylene iodides (VI) are treated withomega-mercapto-1-alkylamines according the following scheme to providecompounds of formula (IX):

Preferred compounds of formula (VIII) and (IX) for practicing theinvention are wherein q=1 and n=2 to 3.

Specific fluoroether alcohols useful in forming polymers of theinvention include those listed in Table 1A. The perfluoroalkyl groups ofthe listed alcohols are linear unless specifically indicated otherwise.

TABLE 1A 1 F₃COCF₂CF₂CH₂CH₂OH, 2 F₃CO(CF₂CF₂)CH₂CH₂OH, 3C₂F₅OCF₂CF₂CH₂CH₂OH, 4 C₂F₅O(CF₂CF₂)CH₂CH₂OH, 5 C₃F₇OCF₂CF₂CH₂CH₂OH, 6C₃F₇O(CF₂CF₂)₂CH₂CH₂OH, 7 C₄F₉OCF₂CF₂CH₂CH₂OH, 8 C₄F₉O(CF₂CF₂)₂CH₂CH₂OH,9 C₆F₁₃OCF₂CF₂CH₂CH₂OH, 10 C₆F₁₃O(CF₂CF₂)₂CH₂CH₂OH, 11F₃COCF(CF₃)CF₂OCF₂CF₂CH₂CH₂OH, 12 F₃COCF(CF₃)CF₂O(CF₂CF₂)₂CH₂CH₂OH, 13C₂F₅OCF(CF₃)CF₂OCF₂CF₂CH₂CH₂OH, 14 C₂F₅OCF(CF₃)CF₂O(CF₂CF₂)₂CH₂CH₂OH, 15C₃F₇OCF(CF₃)CF₂OCF₂CF₂CH₂CH₂OH, 16 C₃F₇OCF₃CF₂O(CF₂CF₂)₂CH₂CH₂OH.

To make the fluoropolymers of the present invention, theperfluoroalkylether ethyl alcohol, or corresponding thiol or amine, isreacted with a polyisocyanate. The polyisocyanate reactant adds to thebranched nature of the polymer. By the term “polyisocyanate” is meantdi- and higher isocyanates and the term includes oligomers. Anypolyisocyanate having predominately two or more isocyanate groups, orany isocyanate precursor of a polyisocyanate having predominately two ormore isocyanate groups, is suitable for use in this invention. Forexample, hexamethylene diisocyanate homopolymers are suitable for useherein and are commercially available. It is recognized that polymerformed from minor amounts of diisocyanates may remain in products madefrom multiple isocyanate groups. An example of this is a biuretcontaining residual small amounts of hexamethylene diisocyanate.

Also suitable for use as the polyisocyanate reactant are hydrocarbondiisocyanate-derived isocyanurate trimers. Preferred is DESMODUR N-3300(a hexamethylene diisocyanate-based isocyanurate also available fromBayer Corporation, Pittsburgh Pa.). Other triisocyanates useful for thepurposes of this invention are those obtained by reacting three moles oftoluene diisocyanate with 1,1,1-tris-(hydroxymethyl)ethane or1,1,1-tris-(hydroxymethyl)propane. The isocyanurate trimer of toluenediisocyanate and that of 3-isocyanatomethyl-3,4,4-trimethylcyclohexylisocyanate are other examples of triisocyanates useful for the purposesof this invention, as is methane-tris-(phenylisocyanate). Precursors ofpolyisocyanate, such as diisocyanate, are also suitable for use in thepresent invention as substrates for the polyisocyanates. DESMODURN-3600, DESMODUR Z-4470, and DESMODUR XP 2410, from Bayer Corporation,Pittsburgh, Pa., and bis-(4-isocyanatocylohexyl)methane are alsosuitable in the invention.

Preferred polyisocyanate reactants are the aliphatic and aromaticpolyisocyanates containing biuret structures, or polydimethyl siloxanecontaining isocyanates. Such polyisocyanates can also contain bothaliphatic and aromatic substituents. Particularly preferred as thepolyisocyanate reactant are hexamethylene diisocyanate homopolymerscommercially available, for instance as DESMODUR N-100, DESMODUR N-75and DESMODUR N-3200 from Bayer Corporation, Pittsburgh, Pa.;3-isocyanatomethyl-3,4,4-trimethylcyclohexyl isocyanate available, forinstance as DESMODUR I (Bayer Corporation);bis-(4-isocyanatocylohexyl)methane available, for instance as DESMODUR W(Bayer Corp) and diisocyanate trimers of formulas (IIa) and (IIb),available as DESMODUR Z2447 and DESMODUR N-3300, respectively, fromBayer Corporation

To make the fluoropolymers of the present invention, theperfluoroalkylether ethyl alcohol, or corresponding thiol or amine, isreacted with a polyisocyanate. Typically a reaction vessel is chargedwith the polyisocyanate; the fluoroalcohol, fluorothiol, fluoroamine, ora mixture thereof; and optionally a non-fluorinated organic compound.The order of reagent addition is not critical. The specific weight ofthe polyisocyanate and other reactants charged is based on theirequivalent weights and on the working capacity of the reaction vessel,and is adjusted so that alcohol, thiol, or amine will be consumed in thefirst step. The charge is agitated and temperature adjusted to about 40°C.-70° C. Typically a catalyst such as a titanium chelate in an organicsolvent is then added and the temperature is raised to about 80° C.-100°C. After holding for several hours, additional solvent and water,linking agent, or a combination thereof, is added and the mixture isallowed to react for several more hours or until all of the isocyanatehas been reacted. More water can then be added along with surfactants,if desired, and stirred until thoroughly mixed. Followinghomogenization, the organic solvent can be removed by evaporation atreduced pressure, and the remaining aqueous solution of thefluoropolymer used as is or subjected to further processing.

A preferred embodiment of the invention is a composition wherein R_(f)is a linear C₁ to C₃ perfluoroalkyl group, and more preferably wherein ris 1, q is 1 and s is 0. Other preferred embodiments are polymerswherein said fluorinated compound reacts with about 5 mol % to about 90mol %, and more preferably about 10 mol % to about 70 mol %, of saidisocyanate groups. Other preferred embodiments are polymers wherein thelinking group is a diamine or polyamine.

In an additional preferred embodiment, step (i) reacting, furthercomprises (d) a non-fluorinated organic compound that contains a singlefunctional group selected from the group of formulaR¹⁰—(R¹¹)_(k)—YHwherein

R¹⁰ is a C₁-C₁₈ alkyl, a C₁-C₁₈ omega-alkenyl radical or a C₁-C₁₈omega-alkenoyl;

R¹¹ is

in which R², R³ and R⁴ are, independently, H or C₁ to C₆ alkyl, and s is1 to 50;

k is 0 or 1; and

Y is —O—, —S—, or —N(R⁵)— in which R⁵ is H or alkyl containing 1 to 6carbon atoms. Preferably the non-fluorinated compound of formulaR¹⁰—(R¹¹)_(k)—YH reacts with about 0.1 mol % to about 60 mol % of saidisocyanate groups.

In another preferred embodiment, the non-fluorinated compound of formulaR¹⁰—(R¹¹)_(k)—YH comprises a hydrophilic water-solvatable materialcomprising at least one hydroxy-terminated polyether of formula (III):

wherein R is a monovalent hydrocarbon radical containing from about oneto about six aliphatic or alicyclic carbon atoms; m and m2 areindependently an average number of repeating oxyethylene (EO) groups,and m1 is an average number of repeating oxypropylene (PO) groups,respectively; provided that m is always a positive integer, while m1 andm2 are a positive integer or zero. When m1 and m2 are zero, formula(III) designates an oxyethylene homopolymer. When m1 is a positiveinteger, and m2 is zero, formula (III) designates a block or randomcopolymer of oxyethylene and oxypropylene. When m1 and m2 are positiveintegers, formula (III) designates a triblock copolymer designatedPEG-PPG-PEG (polyethylene glycol-polypropylene glycol-polyethyleneglycol). More preferably, the hydrophilic, water-solvatable components(3) are the commercially available methoxypolyethylene glycols (MPEG's),or mixtures thereof, having an average molecular weight equal to orgreater than about 200, and most preferably between 350 and 2000. Alsocommercially available and suitable for the preparation of thepolyfluoro organic compounds of the present invention arebutoxypolyoxyalkylenes containing equal amounts by weight of oxyethyleneand oxypropylene groups (Union Carbide Corp. 50-HB Series UCON Fluidsand Lubricants) and having an average molecular weight greater thanabout 1000.

This non-fluorinated compound is reacted in step (i) with thepolyisocyanate and fluorinated compound of formula (I) as describedabove, prior to the reaction with water, linking agent, or a mixturethereof. This initial reaction is conducted so that less than 100% ofthe polyisocyanate groups are reacted. Following this reaction water,linking agent, or a mixture thereof, is added. The reaction of water orlinking agent with the residual NCO groups completely reacts all of theisocyanate groups and eliminates a further purification step that wouldbe needed if other reactants were used at a ratio sufficient to reactwith 100% of the isocyanate groups. Further, this addition greatlyincreases the molecular weight of the polymers and assures proper mixingif more than one reactant is used in the first step of the polyurethanepreparation, i.e. if a water solvatable component is added it is likelythat at least one unit will be present in each polymer.

Linking agents useful in forming polymers of the invention are organiccompounds having two or more Zerewitinoff hydrogen atoms (Zerevitinov,Th., Quantitative Determination of the Active Hydrogen in OrganicCompounds, Berichte der Deutschen Chemischen Gesellschaft, 1908, 41,2233-43). Examples include compounds that have at least two functionalgroups that are capable of reacting with an isocyanate group. Suchfunctional groups include hydroxyl, amino and thiol groups. Examples ofpolyfunctional alcohols useful as linking agents include:polyoxyalkylenes having 2, 3 or 4 carbon atoms in the oxyalkylenegroups, and having two or more hydroxyl groups. Examples includepolyether diols such as polyethylene glycol, polyethyleneglycol-polypropylene glycol copolymers, and polytetramethylene glycol,polyester diols, for instance, the polyester diols derived frompolymerization of adipic acid, or other aliphatic diacids, and organicaliphatic diols having 2 to 30 carbon atoms; non-polymeric polyolsincluding alkylene glycols and polyhydroxyalkanes including1,2-ethanediol, 1,2-propanol diol, 3-chloro-1,2-propanediol;1,3-propanediol, 1,3-butanediol, 1,4-butanediol,2,2-dimethyl-1,3-propanediol, 1,2-, 1,5-, and 1,6-hexanediol,2-ethyl-1,6-hexanediiol, 1,8-octanediol, 1,10-decanediol, glycerine,trimethylolethane, trimethylolpropane,2-ethyl-2-(hydroxymethyl)-1,3-propanediol, 1,2,6-hexanetriol, andpentaerythritol.

Preferred polyfunctional amines useful as linking agents include: amineterminated polyethers such as, for example, JEFFAMINE D400, JEFFAMINEED, and JEFFAMINE EDR-148, all from Huntsman Chemical Co., Salt LakeCity, Utah; aliphatic and cycloaliphatic amines including amino ethylpiperazine, 2-methyl piperazine, 4,4′-diamino-3,3′-dimethyldicyclohexylmethane, 1,4-diaminocyclohexane,1,5-diamino-3-methylpentane, isophorone diamine, ethylene diamine,diethylene triamine, triethylene tetraamine, triethylene pentamine,ethanol amine, lysine in any of its stereoisomeric forms and saltsthereof, hexane diamine, and hydrazine piperazine; and arylaliphaticamines such as xylylenediamine and α,α,α′,α′-tetramethylxylylenediamine.Mono- and di-alkanolamines that can be used as linking agents include:monoethanolamine, monopropanolamine, diethanolamine, dipropanolamine,and the like.

The fluorinated polymers of the present invention are prepared in asuitable dry organic solvent free of groups that react with isocyanategroups. Ketones are the preferred solvents, and methylisobutylketone(MIBK) is particularly preferred for convenience and availability. Thereaction of the alcohols with the polyisocyanate is optionally carriedout in the presence of a catalyst, such as dibutyltindilaurate ortetraisopropyl titanate, typically in an amount of about 0.01 to about1.0% by weight. A preferred catalyst is tetraisopropyl titanate.

The resulting composition is then diluted with water, or furtherdispersed or dissolved in a solvent selected from the groups comprisingsimple alcohols and ketones that are suitable as the solvent for finalapplication to substrates (hereinafter the “application solvent”).

Alternatively, an aqueous dispersion, made by conventional methods withsurfactants, is prepared by removing solvents by evaporation and the useof emulsification or homogenization procedures known to those skilled inthe art. Such solvent-free emulsions are preferred to minimizeflammability and volatile organic compounds (VOC) concerns.

The final product for application to a substrate is a dispersion (ifwater based) or a solution (if solvents other than water are used) ofthe fluorinated polymer.

It will be apparent to one skilled in the art that many changes to anyor all of the above procedures may also be used to optimize the reactionconditions for obtaining maximum yield, productivity or product quality.

The present invention further comprises a method of providing waterrepellency, oil repellency, stain release, hydrophilicity stain release,and cleanability to a substrate comprising contacting the fluorinatedpolymer of the present invention as described above with the substrate.Suitable substrates include fibrous or hard surface substrates asdefined below.

The present invention further comprises a method of providing soilresistance comprising contacting the polymer of the present invention,as a solution or dispersion, with a substrate, provided that the atleast one organic diisocyanate, polyisocyanate, or mixture thereof,comprises one or more cyclic diisocyanates selected from the groupconsisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate,diphenylmethane 4,4′-diisocyanate, diphenylmethane 2,4′-diisocyanate,3-isocyanatomethyl-3,4,4-trimethylcyclohexyl isocyanate,bis-(4-isocyanatocyclohexyl)methane and diisocyanate trimers of formula(IIa) and (IIb):

In this embodiment a preferred method is wherein, within the polymer ofthe invention, said fluorinated compound of formula (I) has p and q eachequal to 1, r equal to 0, X equal to —O—, and R_(f) having 6 carbonatoms. Preferably from about 25% to about 100% by weight, morepreferably from about 50% to about 100% by weight, and more preferablyfrom about 75% to about 100% by weight of the cyclic diisocyanate isemployed.

The polymer of the present invention, in the form of a solution ordispersion, is contacted with the substrate surface by any suitablemethod. Such methods are well known to those skilled in the art, andinclude, for example, application by exhaustion, foam, flex-nip, nip,pad, kiss-roll, beck, skein, winch, liquid injection, overflow flood,roll, brush, roller, spray, dipping, immersion, and the like. Contactingcan also be by use of the conventional beck dyeing procedure, continuousdyeing procedure or thread-line application.

The dispersion or solution is diluted for application until the percenttotal fluorine in the dispersion or solution, based on the weight of thedispersion or solution, is from about 0.001% to about 20%, preferablyfrom about 0.01% to about 15% by weight, and most preferably from about0.1% to about 10% by weight. Application rates for the solution ordispersion of the present invention are in the range of from about 0.5to about 1000 g/m².

The composition of this invention is contacted with the substrate assuch, or in combination with other finishes or surface treating agents.The composition of the present invention optionally further comprisesadditional components such as treating agents or finishes to achieveadditional surface effects, or additives commonly used with such agentsor finishes. Such additional components comprise compounds orcompositions that provide surface effects such as no iron, easy to iron,shrinkage control, wrinkle free, permanent press, moisture control,softness, strength, anti-slip, anti-static, anti-snag, anti-pill, stainrepellency, stain release, soil repellency, soil release, waterrepellency, oil repellency, odor control, antimicrobial, sun protection,and similar effects. One or more such treating agents or finishes can becombined with the blended composition and applied to the fibroussubstrate.

In particular for fibrous substrates, when textiles such as synthetic orcotton fabrics are treated, a wetting agent can be used, such as ALKANOL6112 available from E. I. du Pont de Nemours and Company, Wilmington,Del. When cotton or cotton-blended fabrics are treated, awrinkle-resistant resin can be used such as PERMAFRESH EFC availablefrom Omnova Solutions, Chester, S.C.

Other additives commonly used with such treating agents or finishes canalso be present such as surfactants, pH adjusters, cross linkers,wetting agents, wax extenders, and other additives known by thoseskilled in the art. Suitable surfactants include anionic, cationic, andnonionic. Preferred is an anionic surfactant such as sodium laurylsulfonate, available as DUPONOL WAQE from Witco Corporation, Greenwich,Conn. Examples of such finishes or agents include processing aids,foaming agents, lubricants, anti-stains, and the like. The compositionis applied at a manufacturing facility, retailer location, or prior toinstallation and use, or at a consumer location.

Optionally a blocked isocyanate to further promote durability can beadded to the fluorinated polymers of the present invention (i.e., as ablended isocyanate). An example of a suitable blocked isocyanate isHYDROPHOBAL HYDROPHOBOL XAN available from Ciba Specialty Chemicals,High Point, N.J. Other commercially available blocked isocyanates arealso suitable for use herein. The desirability of adding a blockedisocyanate depends on the particular application for the treating agent.For most of the presently envisioned applications, it does not need tobe present to achieve satisfactory cross-linking between chains orbonding to the substrate. When added as a blended isocyanate, amounts upto about 20% by weight are added.

Optionally, nonfluorinated extender compositions can be included in theapplication composition to obtain some combination of benefits. Examplesof such an optional additional extender polymer composition is thatdisclosed in co-pending U.S. Provisional Application 60/607,612, filedSep. 7, 2004 (CH-2996), and in U.S. Ser. No. 11/175,680 filed Jul. 6,2005 (CH-3048).

The polymers of the present invention are applied to suitable substratesby a variety of customary procedures. For application to washableapparel fabrics, the compounds of the present invention are applied, forexample, from an aqueous dispersion or an organic solvent solution bybrushing, dipping, spraying, padding, roll-coating, foaming or the like.They can be applied to dyed and undyed textile substrates. For textiles,the polymer of the present invention is preferably applied in an amountfrom about 5 g/L to about 100 g/L, more preferably from about 10 g/l toabout 50 g/L.

In the case of a carpet substrate, the “wet pick up” is the amount ofthe dispersion or solution of the present invention applied to thepre-wetted carpet, based on the dry weight of the carpet. A low wetpickup bath system can be interchanged with low wet pickup spray or foamsystems, and a high wet pickup bath system can be interchanged withother high wet pickup systems, e.g., flex-nip system, foam, pad, orflood.

The method employed determines the appropriate wet pickup and whetherthe application is made from one side of the carpet (spray and foamapplications) or both sides (flex-nip and pad). The following Table 2provides typical process specifications for application to carpetsubstrates.

TABLE 2 Application Wet Pickup Range (%) Flex-nip 150-350 Flood 100-500Foam  5-300 Pad 100-500 Spray  5-300

For carpets the percent total fluorine in the dispersion or solution byweight is preferably from about 0.01% to about 20%, more preferably fromabout 0.01% to about 5%, and more preferably from about 0.01% to about2%.

Many variations of the conditions for spray, foam, flex-nip, flood, andpad applications are known to those skilled in the art and the precedingconditions are provided as examples and not are intended to beexclusive. The dispersion or solution of the present invention istypically applied to a pre-wetted carpet at a wet pick up of from about5% to about 500%, and preferably cured at from about 200° F. to about260° F. (104° C. to 127° C.). Alternatively, the treated carpet can beair-dried. To pre-wet the carpet, the carpet is soaked in water and theexcess water suctioned off. The “wet pick up” is the weight of thedispersion or solution of the present invention applied to the carpetbased on the dry weight of the carpet face fiber.

For fibrous substrates in general the amount of polymer applied is anamount sufficient to provide at least 100 micrograms per gram to about5000 micrograms per gram by weight of fluorine based on the weight ofdry substrate. For carpets after drying, the treated carpet preferablycontains about 100 micrograms per gram to about 1000 micrograms per gramfluorine based on the weight of the dried carpet.

Another embodiment of the invention is a method wherein the polymer ofthe invention is applied to a substrate as an additive in a coating.Suitable coating compositions, designated herein as a coating base,include a composition, typically a liquid formulation, of an alkydcoating, Type I urethane coating, unsaturated polyester coating, orwater-dispersed coating, and is applied to a substrate for the purposeof creating a lasting film on the substrate surface. These areconventional paints, stains, and similar coating compositions. Thepolymers of the invention improve the cleanability of the driedcoatings.

By the term “alkyd coating” as used herein is meant a conventionalliquid coating based on alkyd resins, typically a paint, clear coating,or stain. The alkyd resins are complex branched and cross-linkedpolyesters containing unsaturated aliphatic acid residues. Conventionalalkyd coatings utilize, as the binder or film-forming component, acuring or drying alkyd resin. Alkyd resin coatings contain unsaturatedaliphatic acid residues derived from drying oils. These resinsspontaneously polymerize in the presence of oxygen or air to yield asolid protective film. The polymerization is termed “drying” or “curing”and occurs as a result of autoxidation of the unsaturated carbon-carbonbonds in the aliphatic acid component of the oil by atmospheric oxygen.When applied to a surface as a thin liquid layer of formulated alkydcoating, the cured films that form are relatively hard, non-melting, andsubstantially insoluble in many organic solvents that act as solvents orthinners for the unoxidized alkyd resin or drying oil. Such drying oilshave been used as raw materials for oil-based coatings and are describedin the literature.

By the term “urethane coating” as used hereinafter is meant aconventional liquid coating based on Type I urethane resins, typically apaint, clear coating, or stain. Urethane coatings typically contain thereaction product of a polyisocyanate, usually toluene diisocyanate, anda polyhydric alcohol ester of drying oil acids. Urethane coatings areclassified by ASTM D-1 into five categories. Type I urethane coatingscontain a pre-reacted autoxidizable binder as described in SurfaceCoatings Vol. I, previously cited. These are also known as uralkyds,urethane-modified alkyds, oil-modified urethanes, urethane oils, orurethane alkyds, are the largest volume category of polyurethanecoatings and include paints, clear coatings, or stains. The curedcoating is formed by air oxidation and polymerization of the unsaturateddrying oil residue in the binder.

By the term “unsaturated polyester coating” as used hereinafter is meanta conventional liquid coating based on unsaturated polyester resins,dissolved in monomers and containing initiators and catalysts as needed,typically as a paint, clear coating, or gel coat formulation.Unsaturated polyester resins contain as the unsaturated prepolymer theproduct obtained from the condensation polymerization of a glycol suchas 1,2-propylene glycol or 1,3-butylene glycol with an unsaturated acidsuch as maleic (or of maleic and a saturated acid, e.g., phthalic) inthe anhydride form. The unsaturated prepolymer is a linear polymercontaining unsaturation in the chain. This is dissolved in a suitablemonomer, for instance styrene, to produce the final resin. The film isproduced by copolymerization of the linear polymer and monomer by meansof a free radical mechanism. The free radicals can be generated by heat,or more usually by addition of a peroxide, such as benzoyl peroxide,separately packaged and added before use. Such coating compositions arefrequently termed “gel coat” finishes. In order that curing can takeplace at room temperature, the decomposition of peroxides into freeradicals is catalyzed by certain metal ions, usually cobalt. Thesolutions of peroxide and cobalt compound are added separately to themix and well stirred before application. The unsaturated polyesterresins that cure by a free radical mechanism are also suited toirradiation curing using, for instance, ultraviolet light. This form ofcure, in which no heat is produced, is particularly suited to films onwood or board. Other radiation sources, for instance electron-beamcuring, are also used.

By the term “water-dispersed coatings” as used herein is meant coatingsintended for the decoration or protection of a substrate composed ofwater as an essential dispersing component such as an emulsion, latex,or suspension of a film-forming material dispersed in an aqueous phase.“Water-dispersed coating” is a general classification that describes anumber of formulations and includes members of the above describedclassifications as well as members of other classifications.Water-dispersed coatings general contain other common coatingingredients. Water-dispersed coatings are exemplified by, but notlimited to, pigmented coatings such as latex paints, unpigmentedcoatings such as wood sealers, stains, and finishes, coatings formasonry and cement, and water-based asphalt emulsions. A water dispersedcoating optionally contains surfactants, protective colloids andthickeners, pigments and extender pigments, preservatives, fungicides,freeze-thaw stabilizers, antifoam agents, agents to control pH,coalescing aids, and other ingredients. For latex paints the filmforming material is a latex polymer of acrylate acrylic, vinyl-acrylic,vinyl, or a mixture thereof. Such water-dispersed coating compositionsare described by C. R. Martens in “Emulsion and Water-Soluble Paints andCoatings” (Reinhold Publishing Corporation, New York, N.Y., 1965).

By the term “dried coating” as used herein is meant the final decorativeand/or protective film obtained after the coating composition has dried,set or cured. Such a final film can be achieved by, for non-limitingexample, curing, coalescing, polymerizing, interpenetrating, radiationcuring, UV curing or evaporation. Final films can also be applied in adry and final state as in dry coating.

When used as additives the compositions of the present invention areeffectively introduced to the coating base or other composition bythoroughly stirring it in at room or ambient temperature. More elaboratemixing can be employed such as using a mechanical shaker or providingheat or other methods. Such methods are not necessary and do notsubstantially improve the final composition. When used as an additive tocoatings, the compositions of the invention generally are added at about0.001 weight % to about 5 weight % by dry weight of the composition ofthe invention in the wet coating or paint. Preferably about 0.01 weight% to about 1 weight %, and more preferably 0.1 weight % to about 0.5weight % is used. The coating compositions containing the additive ofthe present invention can be applied to a wide variety of fibrous orhard substrates.

The present invention also comprises substrates treated with thecomposition of the present invention. Suitable substrates includefibrous substrates and hard substrates. The fibrous substrates includewoven and nonwoven fibers, yarns, fabrics, fabric blends, paper,leather, and carpets. These are made from natural or synthetic fibersincluding cotton, cellulose, wool, silk, polyamide, polyester,polyolefin, polyacrylonitrile, polypropylene, rayon, nylon, aramid, andacetate. By “fabric blends” is meant fabric made of two or more types offibers. Typically these blends are a combination of at least one naturalfiber and at least one synthetic fiber, but also can include a blend oftwo or more natural fibers or of two or more synthetic fibers. Carpetsubstrates can be dyed, pigmented, printed, or undyed. Carpet substratescan be scoured or unscoured. Substrates to which it is particularlyadvantageous to apply the polymers of the present invention so as toimpart soil resistant properties include those prepared from polyamidefibers (such as nylon), cotton and blends of polyester and cotton,particularly such substrates being used in tablecloths, garments,washable uniforms and the like.

The hard surface substrates include porous and non-porous mineralsurfaces, such as glass, stone, masonry, concrete, unglazed tile, brick,porous clay and various other substrates with surface porosity. Specificexamples of such substrates include unglazed concrete, brick, tile,stone (including granite and limestone), grout, mortar, marble,limestone, statuary, monuments, wood, composite materials such asterrazzo, and wall and ceiling panels including those fabricated withgypsum board.

Such substrates have enhanced cleanability when coated with a coatingcomposition containing the composition of the present invention. Thecompositions of the present invention are useful to provide one or moreof excellent water repellency, oil repellency, soil resistance, stainrelease, hydrophilicity stain release, and cleanability to treatedsubstrates. These properties are obtained using lower fluorineconcentrations compared with conventional perfluorocarbon surfacetreatment agents, providing improved “fluorine efficiency” in theprotection of treated surfaces. The compositions of the presentinvention also allow for the use of shorter fluoroalkyl groupscontaining 6 or fewer carbon atoms while conventional commerciallyavailable surface treatment products typically show poor oil repellencyand water repellency performance if the fluoroalkyl groups contain less8 carbon atoms.

The following examples are intended only to illustrate the invention,and should not be interpreted so as to limit the invention in any way.

Materials and Test Methods

The following materials and test methods were used in the examplesherein.

Materials

Residential Carpet

The carpet used for testing in the Examples 2 to 6 consisted of aresidential loop carpet construction (30 oz/sq yd) (1112.4 g/m²) havinga nylon 6,6 face fiber that had been dyed to a beige color and hadreceived a stain resist treatment of 1.2% SR-500 (100% solids basis).Carpet was obtained from Invista, Inc., Wilmington, Del. SR-500 isavailable from E. I. duPont de Nemours and Company, Wilmington, Del.

The carpets received a pre-spray application of water at 25% wetpick-up. The carpets were then treated with spray application of thedispersed fluoropolymers of Examples 2 to 6 at 25% wet pick-up. Thedispersions were diluted with water, to the degree necessary to obtain afluorine content of 400 ppm fluorine delivered to the carpet using 25%wet pick-up. Wet pick-up is the weight of the dispersion or solution ofthe polymer of the present invention applied to the carpet, based on thedry weight of the carpet face fiber. The treated carpet was then driedto a carpet fiber face temperature of 250° F. (121° C.). The applicationlevels for the compositions were such to provide a fluorine level aslisted in Tables 6 and 7.

Commercial Carpet

The carpet used for testing of Examples 1 and 3 to 6 consisted of acommercial loop carpet construction (28 oz/sq yd) (1038.2 g/m²) having anylon 6,6 face fiber that had been dyed to a yellow color. Carpet wasobtained from Invista, Inc., Wilmington, Del. SR-500 is available fromE. I. duPont de Nemours and Company, Wilmington, Del.

The carpets for received a pre-spray application of water at 25% wetpick-up. The carpets were then treated with spray application of thedispersed fluoropolymers of Examples 1 and 3 to 6 at 25% wet pick-up.The dispersions were diluted with water, to the degree necessary toobtain a fluorine content of 600 ppm fluorine delivered to the carpetusing 25% wet pick-up. Wet pick-up is the weight of the dispersion orsolution of the polymer of the present invention applied to the carpet,based on the dry weight of the carpet face fiber. The treated carpet wasthen dried to a carpet fiber face temperature of 250° F. (121° C.). Theapplication levels for the compositions were such to provide a fluorinelevel as listed in Tables 6 and 7.

Test Method 1—Water Repellency

The water repellency of a treated substrate was measured according toAATCC standard Test Method No. 193-2004 and the DuPont TechnicalLaboratory Method as outlined in the TEFLON Global Specifications andQuality Control Tests information packet. The test determines theresistance of a treated substrate to wetting by aqueous liquids. Dropsof water-alcohol mixtures of varying surface tensions are placed on thesubstrate and the extent of surface wetting is determined visually. Thehigher the water repellency rating, the better the resistance of afinished substrate to staining by water-based substances.

The water repellency test liquids are shown in Table 3.

TABLE 3 Water Repellency Test Liquids Vol % Water RepellencyComposition, Distilled Rating Number Isopropyl Alcohol Water 1 2 98 2 595 3 10 90 4 20 80 5 30 70 6 40 60 7 50 50 8 60 40 9 70 30 10 80 20 1190 10 12 100 0

Testing procedure: Three drops of Test Liquid 1 are placed on thetreated substrate. After 10 seconds, the drops are removed by usingvacuum aspiration. If no liquid penetration or partial absorption(appearance of a darker wet patch on the substrate) is observed, thetest is repeated with Test Liquid 2. The test is repeated with TestLiquid 3 and progressively higher Test Liquid numbers until liquidpenetration (appearance of a darker wet patch on the substrate) isobserved. The test result is the highest Test Liquid number that doesnot penetrate into the substrate. Higher scores indicate greaterrepellency.

Test Method 2—Oil Repellency

The treated samples were tested for oil repellency by a modification ofAATCC standard Test Method No. 118, conducted as follows. A substratetreated with an aqueous dispersion of polymer as previously described,is conditioned for a minimum of 2 hours at 23° C. and 20% relativehumidity and 65° C. and 10% relative humidity. A series of organicliquids, identified below in Table 4, are then applied dropwise to thesamples. Beginning with the lowest numbered test liquid (RepellencyRating No. 1), one drop (approximately 5 mm in diameter or 0.05 mLvolume) is placed on each of three locations at least 5 mm apart. Thedrops are observed for 30 seconds. If, at the end of this period, two ofthe three drops are still spherical in shape with no wicking around thedrops, three drops of the next highest numbered liquid are placed onadjacent sites and similarly observed for 30 seconds. The procedure iscontinued until one of the test liquids results in two of the threedrops failing to remain spherical to hemispherical, or wetting orwicking occurs.

The oil repellency rating is the highest numbered test liquid for whichtwo of the three drops remained spherical to hemispherical, with nowicking for 30 seconds. In general, treated samples with a rating of 5or more are considered good to excellent; samples having a rating of oneor greater can be used in certain applications.

TABLE 4 Oil Repellency Test Liquids Oil Repellency Rating Number TestSolution 1 NUJOL Purified Mineral Oil 2 65/35 NUJOL/n-hexadecane byvolume at 21° C. 3 n-hexadecane 4 n-tetradecane 5 n-dodecane 6 n-decane7 n-octane 8 n-heptane Note: NUJOL is a trademark of Plough, Inc., for amineral oil having a Saybolt viscosity of 360/390 at 38° C. and aspecific gravity of 0.880/0.900 at 15° C.Test Method 3—Accelerated Soiling Drum Test.

A drum mill (on rollers) was used to tumble synthetic soil onto carpetsamples. Synthetic soil was prepared as described in AATCC Test Method123-2000, Section 8. Soil-coated beads were prepared as follows.Synthetic soil, 3 g, and 1 liter of clean nylon resin beads (SURLYNionomer resin beads ⅛- 3/16 inch (0.32-0.48 cm) diameter were placedinto a clean, empty canister. SURLYN is an ethylene/methacrylic acidcopolymer, available from E. I. du Pont de Nemours and Co., WilmingtonDel.). The canister lid was closed and sealed with duct tape and thecanister rotated on rollers for 5 minutes. The soil-coated beads wereremoved from the canister.

Carpet samples to insert into the drum were prepared as follows. Totalcarpet sample size was 8×25 inch (20.3×63.5 cm) for these tests. Onetest sample and one control sample were tested at the same time. Thecarpet pile of all samples was laid in the same direction. The shorterside of each carpet sample was cut in the machine direction (with thetuft rows). Strong adhesive tape was placed on the backside of thecarpet pieces to hold them together. The carpet samples were placed inthe clean, empty drum mill with the tufts facing toward the center ofthe drum. The carpet was held in place in the drum mill with rigidwires. Soil-coated resin beads, 250 cc, and 250 cc of ball bearings (5/16 inch, 0.79 cm diameter) were placed into the drum mill. The drummill lid was closed and sealed with duct tape. The drum was run on therollers for 2½ minutes at 105 rpm. The rollers were stopped and thedirection of the drum mill reversed. The drum was run on the rollers foran additional 2½ minutes at 105 rpm. The carpet samples were removed andvacuumed uniformly to remove excess dirt. The soil-coated beads werediscarded.

The Delta E color difference for the soiled carpet was measured for thetest and control items versus the original unsoiled carpet. Colormeasurement of each carpet was conducted on the carpet following theaccelerated soiling test. For each control and test sample the color ofthe carpet was measured, the sample was soiled, and the color of thesoiled carpet was measured. The Delta E is the difference between thecolor of the soiled and unsoiled samples, expressed as a positivenumber. The color difference was measured on each item, using a MinoltaChroma Meter CR-310. Color readings were taken at five different areason the carpet sample, and the average Delta E was recorded. The controlcarpet for each test item was of the same color and construction as thetest item. The control carpet had not been treated with anyfluorochemical. A lower Delta E indicates less soiling and superior soilresistance.

Test Method 4—Wicking Test

For the wicking testing, 5 drops of DI water were placed on the cottonsamples on different areas of the material. The time (in seconds) ittook to completely absorb into the cotton was recorded. 180 Seconds (3minutes) was the point where, if the drop had not been absorbed, thetest was rated as a fail. Wicking is an indication of hydrophilicity,and test results are referred to herein either as wicking orhydrophilicity stain release.

Test Method 5—Stain Release

The stain release test was taken from the AATCC Test Method 130-1995.Five drops of either mineral oil or corn oil were placed in the centerof the treated cotton sample on a piece of blotter paper. A piece ofglassine paper (weighing paper) was placed over the spot and afive-pound weight was placed on top of the paper. After 60 seconds, theweight and glassine paper were removed. Four red dots were marked aroundthe oil spot. The cotton material was placed in the Kenmore washingmachine with the following settings of Large load, Warm (100° F.)/Cold,One rinse, Ultra Clean (setting 12), and Normal (fast/slow). Then 100 gof AATCC WOB detergent and 4 lbs. of material including ballasts wereadded to the washing machine. After washing, the samples were placed inthe Kenmore dryer on the high setting for 45 minutes. The samples wererated based on the Stain Release Replica.

TABLE 5 Stain Release Grades Grade 5 Stain equivalent to Standard Stain5 Grade 4 Stain equivalent to Standard Stain 4 Grade 3 Stain equivalentto Standard Stain 3 Grade 2 Stain equivalent to Standard Stain 2 Grade 1Stain equivalent to Standard Stain 1 Grade 5 represents the best stainremoval and Grade 1 the poorest stain removal.Test Method 6—Wash Durability

The fabric samples were washed following the washing procedure ofInternational Standard for textile testing. Fabric samples are loadedinto a horizontal drum, front-loading type (Type A, WASCATORFom71MP-Lab) of automatic washing machine with a ballast load to give atotal dry load of 4lb. A commercial detergent is added (AATCC 1993standard Reference Detergent WOB) and the washer programmed with highwater level with warm water (105° F., 41° C.), 15 minutes normal washcycle followed by 2 times 13 minutes rinse and then 2 minutes spin dry.The sample and ballast are washed a designated number of times (5 HW for5 washes, 20 HW for 20 washes etc.). After washing, the samples wereplaced in the Kenmore dryer on the high setting for 45 minutes. Thesamples are again tested for stain release using Test Methods 4 and 5.Testing for hydrophilic stain release (wicking) was on 100% AvondaleCotton based on same weight loading (bath concentration 30 g/L)

Test Method 7-Leneta Oil Cleanability Test

The test method described herein is a modification of ASTM3450-00—Standard Test Method for Washability Properties of InteriorArchitectural Coatings, which is hereby specifically incorporated byreference.

Drawdowns were prepared by applying a coat of coating composition onLeneta Black MYLAR cards (The Leneta Company, Mahwah, N.J.) using aBYK-Gardner automatic drawdown machine (BYK-Gardner, Silver Spring, Md.)and a 5 mil (0.127 mm) Bird applicator drawdown blade (BYK-Gardner,Silver Spring, Md.). The drawdown speed was set to be slow enough toprevent pinholes or holidays in the resulting coating. Several drawdownswere prepared for each paint and additive combination. The coated cardswere allowed to dry for seven days for testing for cleanability.

Staining media were prepared using VASELINE NURSERY JELLY (MariettaCorporation, Cortland, N.Y.) and Leneta Carbon Black Dispersion inMineral Oil (ST-1) (The Leneta Company, Mahwah, N.J.). The petroleumjelly was melted in a clean glass container for 30 minutes in an ovenset at 70° C. Then the petroleum jelly was mixed with 5% of its weightof Leneta Carbon Black. For instance, 95 g of petroleum jelly was mixedwith 5 g of Leneta Carbon Black to produce 100 g of staining media. Themixed staining media was cooled for several hours in a refrigerator at4° C.

Cleaning media were prepared using a JOY ULTRA CONCENTRATED COUNTRYLEMON dishwashing liquid (The Procter & Gamble Company, Cincinnati,Ohio). Dishwashing liquid was mixed with deionized water at a ratio of 1g of dishwashing liquid for every 99 g of water.

Each drawdown was stained in the same manner. A staining template wasprepared from a MYLAR Leneta card by cutting out a 3″ by 1″ (7.6 cm by2.5 cm) strip from the interior of the card. The template was placedover a coated drawdown card to be stained. Staining media was spreadover the drawdown card and the template using a spatula so that none ofthe drawdown card remained visible. Excess stain was removed with aspatula. Stained cards were allowed to set and dry for 60 minutes.

In preparation for cleaning, scrap MYLAR was used to gently scrape theexcess dried stain from the stained section of the card, both the washedand unwashed sections. Similarly a c-folded clean paper towel was usedto remove unset stain from the entire card, both the washed and unwashedsections. The card was then securely attached to a BYK-Gardner Abrasiontester (BYK-Gardner, Silver Spring, Md.) or other method. A piece ofcheesecloth (VWR International, San Diego, Calif.) was attached to thecleaning block on the abrasion tester. The cheesecloth was folded andattached so that the contacting surface was 8 layers thick. 10 mL ofcleaning solution prepared as specified above was applied to thecontacting surface of the cheesecloth. The abrasion tester was runthrough 5 cycles (10 wipes) over a stained section of the drawdown cardthat is henceforth designated as stained and cleaned. Excess cleaningsolution was rinsed away with deionized water for a few seconds and thenallowed to dry for 2 hours or until completely dry by visibleinspection. One section of each stained drawdown card was cleaned inthis manner.

Cleanability was determined by evaluating the stained and washed paintedportion of the drawdown card in comparison to both the unstained andpainted portion of the card and the stained and unwashed painted portionof the card. A HunterLab ULTRASCAN Pro colorimeter (Hunter AssociatesLaboratory, Inc, Reston, Va.) was used to take three differentmeasurements for each designated painted portion of the drawdown card:stained and washed, unstained, and stained and unwashed. Themeasurements were averaged to obtain a mean value for that section thatis used to evaluate the cleanability rating for that card as describedbelow. The colorimeter was set to read the L* function and the aperturewas no larger than ¾ of an inch (1.9 cm).

A cleanability score was calculated ranging from 0-10 wherein 0 isuncleanable, and 10 is completely cleanable. Values 1-9 were establishedin numerical order equidistant from 0, 10, and one another on a linearslope. The above description fits the following equation: [(mean L*value of stained and washed painted section)−(mean L* value of stainedand unwashed painted section)]/[(mean L* value of unstained paintedsection)−(mean L* value of stained and unwashed paintedsection)]*10=cleanability rating.

EXAMPLES Example 1

C₃F₇OCF₂CF₂I (100 g, 0.24 mol) and benzoyl peroxide (3 g) were chargedto a pressure vessel under nitrogen. A series of three vacuum/nitrogengas sequences was then executed at −50° C. and ethylene (18 g, 0.64 mol)was introduced. The vessel was heated for 24 hour at 110° C. Theautoclave was cooled to 0° C. and opened after degassing. Then theproduct was collected in a bottle. The product was distilled giving 80 gof C₃F₇OCF₂CF₂CH₂CH₂₁ in 80% yield. The boiling point was 56˜60° C. at25 mm Hg (3333 Pa).

A mixture of C₃F₇OCF₂CF₂CH₂CH₂I (300 g, 0.68 mol) and N-methyl-formamide(300 mL), was heated to 150° C. for 26 h. Then the reaction was cooledto 100° C., followed by the addition of water to separate the crudeester. Ethyl alcohol (77 mL) and p-toluene sulfonic acid (2.59 g) wereadded to the crude ester, and the reaction was stirred at 70° C. for 15minutes. Then ethyl formate and ethyl alcohol were distilled out to givea crude product. The crude product was dissolved in ether, washed withaqueous sodium sulfite, water, and brine in turn, then dried overmagnesium sulfate. The product was then distilled to give 199 g ofC₃F₇OCF₂CF₂CH₂CH₂OH in 85% yield. The boiling point was 71˜73° C. at 40mm Hg (5333 Pa).

To a 3-neck 250 mL round-bottom flask, equipped with a reflux condenserwith a nitrogen inlet, a magnetic stirrer, and a temperature probe, wasadded C₃F₇OCF₂CF₂CH₂CH₂OH alcohol (20.30 g, 61.50 mmol) that was driedover sodium sulfate, and DESMODUR N100 (63% in methyl isobutyl ketone,MIBK, 23.43 g, 78.11 mmol NCO). The mixture was heated to 55° C. To thesolution, dibutyl tin dilaurate (2.0 g of 0.4 wt % catalyst in MIBK) wasadded dropwise resulting in an exotherm of 30° C. The reaction was heldat 84° C. for 2 h. MIBK (28.75 g) and water (0.23 g) were added dropwiseto the reaction followed by heating for 24 h at 84° C. until isocyanatewas no longer detected, using a Colormetric Technologies, Inc isocyanatetest strip. The hot product (20.0 g) was added to a hot surfactantsolution (70° C., 20 g deionized water and 1.63 g Witco C6094surfactant). The solution was homogenized using a digital sonifier for 5minutes and MIBK was removed via vacuum distillation to yield a stabledispersion of the urethane polymer (15.5% solids, 6.11% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1, for oil repellency by Test Method 2 Results are listed in Table 6.

Example 2

The sample was prepared using the method described for Example 1, exceptthat the hot product (20.0 g) was added to a hot surfactant solution(70° C., 20 g deionized water, 0.32 g MERPOL SE and 1.46 g ARQUAD 16-50surfactants). The solution was homogenized using a digital sonifier for5 minutes and MIBK was removed via vacuum distillation to yield a stabledispersion of urethane polymer (15.5% solids, 5.51% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1 and for oil repellency by Test Method 2. Results are listed in Table6.

Example 3

To a 3-neck 250 mL round-bottom flask, equipped with a reflux condenserwith a nitrogen inlet, a magnetic stirrer, and a temperature probe, wasadded C₃F₇OCF₂CF₂CH₂CH₂OH alcohol prepared as in Example 1 (24.65 g,74.67 mmol) that was dried over sodium sulfate, and DESMODUR N3300(17.98 g, 93.34 mmol (NCO)) in 11 g MIBK. The mixture was heated to 65°C. To the solution, dibutyl tin dilaurate (2.4 g of 0.4 wt % catalyst inMIBK) was added dropwise resulting in an exotherm of 30° C. The reactionwas held at 84° C. for 3 h. MIBK (34.40 g) and water (0.27 g) were addeddropwise to the reaction followed by heating for 24 h at 84° C.Additional water 0.27 g was added and the reaction was heated untilisocyanate was no longer detected. The hot product (40.0 g) was added toa hot surfactant solution (70° C., 65 g deionized water and 3.09 g WitcoC6094 surfactant). The solution was homogenized using a digital sonifierfor 5 min and MIBK was removed via vacuum distillation to yield a stabledispersion (24% solids, 8.9% F).

The dispersion was applied to carpet as described above under“Materials”. The carpet was tested for water repellency, and oilrepellency using Test Methods 1 and 2 respectively. The resulting dataare in Table 6.

Example 4

The sample was prepared using the method described for Example 3, exceptthat the hot product (12.5.0 g) was added to a hot surfactant solution(70° C., 12.5 g deionized water, 0.70 g SADPO and 0.05 g TERGITOLsurfactant). The solution was homogenized using a digital sonifier for 5minutes and MIBK was removed via vacuum distillation to yield a stabledispersion (24% solids, 8.9% F).

The dispersion was applied to carpet as described above under“Materials”. The carpet was tested for water repellency and oilrepellency using Test Methods 1 and 2 respectively. The resulting dataare in Table 6.

Example 5

To a 4-neck 500 mL round-bottom flask, equipped with a reflux condenserwith a nitrogen inlet, an overhead stirrer, and a temperature probe, wasadded C₃F₇OCF₂CF₂CH₂CH₂OH alcohol prepared as in Example 1 (19.00 g,57.58 mmol) that was dried over sodium sulfate, butyl acetate (3 g), andDESMODUR Z4470 (70% in butyl acetate, 27.10 g, 76.77 mmol NCO). Themixture was heated to 65° C. To the solution, dibutyl tin dilaurate (1.4g of 0.4 wt % catalyst in MIBK) was added dropwise resulting in anexotherm of 17° C. The reaction was held at 84° C. for 4 h. Butylacetate (32 g) and water (0.35 g) were added dropwise to the reactionfollowed by heating for 8 h at 84° C. Butyl acetate (20 g) and water(0.35 g) were added and heating continued for 5 h until isocyanate wasno longer detected. The hot product (15.0 g) was added to a hotsurfactant solution (70° C., 28 g deionized water, 0.24 g Merpol SE and1.107 g Arquad 16-50 surfactants). The solution was homogenized using adigital sonifier for 5 min and butyl acetate was removed via vacuumdistillation to yield a stable dispersion of urethane polymer (20.0%solids, 4.6% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1, for oil repellency by Test Method 2. Soiling performance of thecarpets was evaluated by Test Method 3 accelerated soiling test andevaluated by the color measurement of soiling performance. Results arelisted in Tables 6 and 7.

Example 6

The sample was prepared using the method described for Example 5, exceptthat the hot product (15.0 g) was added to a hot surfactant solution(70° C., 28 g deionized water, 0.07 g BRIG 58 and 0.30 g ARQUAD 2HT-75surfactants). The solution was homogenized using a digital sonifier for5 minutes and butyl acetate was removed via vacuum distillation to yielda stable dispersion (20.0% solids, 5.0% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1, for oil repellency by Test Method 2. Soiling performance of thecarpets was evaluated by Test Method 3 accelerated soiling test andevaluated by the color measurement of soiling performance. Results arelisted in Tables 6 and 7.

TABLE 6 Carpet Repellency Example Type of Final ppm Repellency No CarpetF^(a) Water Oil 1 Commercial 600 4 4 2 Residential 400 4 4 3 Residential400 4 3 4 Residential 400 4 3 3 Commercial 600 4 4 4 Commercial 600 4 45 Residential 400 5 2 6 Residential 400 5 2 5 Commercial 600 4 2 6Commercial 600 5 2

The data in Table 6 demonstrates that oil and water repellency wereachieved using multiple isocyanate reactants and surfactant packages.

TABLE 7 Soil Resistance Example Type of Carpet Final PPM F Delta EUntreated Residential 0 21.54 5 Residential 400 16.87 6 Residential 40016.81 Untreated Commercial 0 34.88 5 Commercial 600 27.18 6 Commercial600 28.75

The data is Table 7 demonstrates that Examples 5 and 6 were functionalsoil resists for both commercial and residential carpets.

Example 7

Under a nitrogen gas blanket the flask was charged with DESMODUR N100(63% in MIBK, 22.1 g, 0.0736 mol NCO), methoxypolyoxyethylene glycol(MPEG 750, molecular weight of about 750, 11.95 g, 0.0147 mol) andC₃F₇OCF₂CF₂CH₂CH₂OH (10 g, 0.03 mol) prepared as in Example 1. Thereaction mixture was heated to 65° C., followed by adding 5% by weighttitanium (IV) isopropoxide in methyl isobutyl ketone (MIBK) (1.2 g).After 3 h at 95° C., MIBK (13.6 mL) and water (4.6 mL) were added at 85°C. Once water was added the temperature was dropped to 75° C. andallowed to stir overnight. More water (80.46 mL) was added to thereaction and stirred for 0.5 h. After evaporating MIBK at reducedpressure, the resulting polymer was obtained (26.04 solids).

Fabric samples, 100% Avondale cotton, were treated with the water basedfluorinated polymer formulation using a conventional pad bath (dipping)process. A bath containing 30-50 g/L of the fluorinated polymer treatingagent was used. After application, the fabric samples were cured atapproximately 165° C. for 2 minutes, and allowed to “rest” aftertreatment and cure. The samples were tested for wicking, stain releaseand wash durability using Test Methods 4, 5 and 6 respectively. Resultsare in Table 8.

Example 8

C₂F₅OCF₂CF₂I (116 g, 0.32 mol) and benzoyl peroxide (4 g) were chargedto a vessel under nitrogen. A series of three vacuum/nitrogen gassequences was then executed at −50° C. and ethylene (24 g, 0.86 mol) wasintroduced. The vessel was heated for 24 h at 110° C. The autoclave wascooled to 0° C. and opened after degassing. The product was collected ina bottle. Six runs were combined, and the product distilled to provideC₂F₅OCF₂CF₂CH₂CH₂I (470 g, 64% yield, bp 135˜137° C. at 760 mm Hg(1013×10² Pa)).

A flask was charged with 130 g of C₂F₅OCF₂CF₂CH₂CH₂₁, 643 mL of theN-methylpyrrolidone and 48 mL of deionized water. The mixture was heatedto 132° C. for 20 h. Deionized water was added and the lower layer wasseparated. The lower layer was dissolved in ether, washed with saturatedsodium sulfite solution, and dried over anhydrous sodium sulfate. Afterrotary vaporization 48 g of C₂F₅OCF₂CF₂CH₂CH₂OH in 52% yield, bp 70˜72°C. at 60 mm Hg. (7999 Pa).

Under a nitrogen gas blanket a flask was charged with DESMODUR N-100(63% in MIBK, 21.02 g, 0.07 mol NCO), methoxypolyoxyethylene glycol(MPEG 750, 10.5 g, 0.014 mol) and C₂F₅OCF₂CF₂CH₂CH₂OH (8.0 g, 0.028mol). The mixture was heated to 65° C., followed by adding 5% titanium(IV) isopropoxide in MIBK (1.15 g). After 3 h at 95° C., MIBK (13 mL)and water (4.16 mL) were added at 85° C. Once the water was added, thetemperature was dropped to 75° C. and the liquid allowed to stirovernight. More water (76.71 mL) was added to the reaction and stirredfor 0.5 h. After evaporating MIBK at reduced pressure, the resultingpolymer was obtained (29.05% solids).

Fabric samples, 100% Avondale cotton, were treated with the water basedfluorinated polymer formulation using a conventional pad bath (dipping)process. A bath containing 30-50 g/L of the fluorinated polymer treatingagent was used. After application, the fabric samples were cured atapproximately 165° C. for 2 minutes, and allowed to “rest” aftertreatment and cure. The samples were tested for wicking, stain releaseand wash durability using Test Methods 4, 5 and 6 respectively. Resultsare in Table 8.

Example 9

CF₃OCF₂CF₂I (285 g, 0.91 mol) and benzoyl peroxide (12 g) were chargedto a vessel under nitrogen. A series of three vacuum/nitrogen gassequences were then executed at −50° C., after which ethylene (69 g,2.46 mol) was introduced. The vessel was heated for 24 hours at 110° C.The autoclave was cooled to 0° C. and opened after degassing. Then theproduct was collected in a bottle. Two runs were combined and theproduct was distilled giving 292 g of CF₃OCF₂CF₂CH₂CH₂I in 50% yield.The boiling point of the product was 56˜60° C. at 60 mmHg pressure [7999Pa].

A mixture of CF₃OCF₂CF₂CH₂CH₂I, (92 g, 0.27 mol) and N-methyl-formamide(119 mL), was heated to 150° C. for 26 hours. Then the reaction wascooled to 100° C., followed by the addition of water to separate thecrude ester. Ethyl alcohol (30 mL) and p-toluene sulfonic acid (1.03 g)were added to the crude ester, and the reaction was stirred at 70° C.for 15 minutes. Then ethyl formate and ethyl alcohol were distilled outto give a crude product. The crude product was dissolved in ether,washed with aqueous sodium sulfite, water, and brine in turn, then driedover magnesium sulfate. The product CF₃OCF₂CF₂CH₂CH₂OH was thendistilled to give 44 g product in 71% yield.

Under a nitrogen gas blanket the flask was charged with DESMODUR N-100(63% in MIBK, 19.11 g, 0.0647 mol NCO), methoxypolyoxyethylene glycol(MPEG 750, 9.59 g, 0.013 mol) and CF₃OCF₂CF₂CH₂CH₂OH (6 g, 0.026 mol).The reaction mixture was heated to 65° C., followed by adding 5%titanium (IV) isopropoxide in MIBK (1.04 g). After 3 hours at 95° C.,MIBK (11.82 mL) and water (3.78 mL) were added at 85° C. Once water wasadded the temperature was dropped to 75° C. and the liquid allowed tostir overnight. More water (69.73 mL) was added to the reaction andstirred for 0.5 hour. After evaporating MIBK at reduced pressure, theresulting polymer (27.05% solids) was obtained.

Fabric samples, 100% Avondale cotton, were treated with the water basedfluorinated polymer formulation using a conventional pad bath (dipping)process. A bath containing 30-50 g/L of the fluorinated polymer treatingagent was used. After application, the fabric samples were cured atapproximately 165° C. for 2 minutes, and allowed to “rest” aftertreatment and cure. The samples were tested for wicking, stain releaseand wash durability using Test Methods 4, 5 and 6 respectively. Resultsare in Table 8.

Comparative Example A

The procedure of Example 7 was employed, but using as the fluorochemicala perfluoroalkylethyl alcohol mixture of the formula F(CF₂)_(a)CH₂CH₂OH,wherein a ranged from 6 to 14, and was predominately 6, 8, and 10. Thetypical mixture was as follows: 27% to 37% of a=6, 28% to 32% of a=8,14% to 20% of a=10, 8% to 13% of a=12, and 3% to 6% of a=14.

Fabric samples, 100% Avondale cotton, were treated with the water basedfluorinated polymer formulation using a conventional pad bath (dipping)process. A bath containing 30-50 g/L of the fluorinated polymer treatingagent was used. After application, the fabric samples were cured atapproximately 165° C. for 2 minutes, and allowed to “rest” aftertreatment and cure. The samples were tested for wicking, stain releaseand wash durability using Test Methods 4, 5 and 6 respectively. Resultsare in Table 8.

TABLE 8 Comparative Example A Example 7 Example 8 Example 9 % Fluorine0.3   0.19   0.18 0.14 Wicking (Horz/sec) Initial >180 7 10  6 5HW 23 32 1 Stain Release- Initial Mineral oil 4 4  3+ 4 Corn Oil 4 4  3+ 3Stain Release- 5HW Mineral Oil 4 4 3 3 Corn Oil 4  3+  3+ 3

The data in Table 8 demonstrates that the compositions of the presentinvention (Examples 7-9) had excellent stain release property, generallycomparable to the control (Comparative Example A). They gave a muchbetter hydrophilicity, with ratings of 1 to 10 seconds initial wickingtime, compared to the control rating of >180 seconds wicking time usingthe homologue mixture. Therefore the polymer of the present invention isa good hydrophilic stain release product compared to Comparative ExampleA.

Example 10

Under a nitrogen gas blanket a flask was charged with DESMODUR N-100D(63% in MIBK, 8.79 g, 0.03 mol NCO), methoxypolyoxyethylene glycol (MPEG350, molecular weight of about 350.)(4.4 g, 0.0125 mol) andC₃F₇OCF₂CF₂CH₂CH₂OH (4.13 g, 0.0125 mol) prepared as in Example 1. Thereaction mixture was heated to 55° C., followed by adding 0.4% dibutyltin dilaurate in methyl isobutyl ketone (MIBK) methyl isobutyl ketone(0.35 g). After 16 h at 90° C., water (0.225 g) was added at 60° C. andreaction was stirred for 3 h. MIBK (4 mL) and water (31.5 mL) were addedand the reaction was stirred for 1 h. After evaporating MIBK at reducedpressure, the resulting product was poured into a bottle for coatingtesting.

The product was added to acrylic latex paint at the level indicated inTable 9 based upon dry weight of the polymer. The samples were testedfor cleanability using Test Method 7. Results are in Table 9.

Example 11

Under a nitrogen gas blanket a flask was charged with DESMODUR N-100(63% in MIBK, 8.79 g, 0.03 mol NCO), methoxypolyoxyethylene glycol (MPEG350, molecular weight of about 350)(4.4 g, 0.0125 mol) andC₂F₅OCF₂CF₂CH₂CH₂OH (3.5 g, 0.0125 mol) prepared as in Example 8. Thereaction mixture was heated to 55° C., followed by adding 0.4% dibutyltin dilaurate in methyl isobutyl ketone (MIBK) (0.35 g). After 16 h at90° C., water (0.225 g) was added at 60° C. and reaction was stirred for3 h. MIBK (4 mL) and water (31.5 mL) were added and the reaction wasstirred for 1 h. After evaporating MIBK at reduced pressure, thematerial was poured into a bottle for coating test.

The product was added to acrylic latex paint at the level indicated inTable 9 based upon dry weight of the polymer. The samples were testedfor cleanability using Test Method 7. Results are in Table 9.

Example 12

Under a nitrogen gas blanket a flask was charged with DESMODUR N-100(63% in MIBK, 8.79 g, 0.03 mol NCO), methoxypolyoxyethylene glycol (MPEG350, molecular weight of about 350)(4.4 g, 0.0125 mol) andCF₃OCF₂CF₂CH₂CH₂OH (2.9 g, 0.0125 mol) prepared as in Example 9. Thereaction mixture was heated to 55° C., followed by adding 0.4% dibutyltin dilaurate in methyl isobutyl ketone (MIBK) (0.35 g). After 16 h at90° C., water (0.225 g) was added at 60° C. and reaction was stirred fro3 h. MIBK (4 mL) and water (31.5 mL) were added and the reaction wasstirred for 1 h. After evaporating MIBK at reduced pressure, thematerial was poured into a bottle for coating test.

The product was added to flat acrylic latex paint having 3% gloss at 85degrees at the level indicated in Table 9 based upon dry weight of thepolymer. The Examples were added to the base coating in an amount toachieve a fluorine content of 675 microgram/gram F based on the weightof the wet paint. The samples were tested for cleanability using TestMethod 7. Results are in Table 9.

TABLE 9 Cleanability Examples* Weight % Cleanability Rating Control^(a)3.8 10 2.34 5.3 11 1.69 6.1 12 2.27 5.2 *Examples 10, 11 and 12 hadequivalent fluorine content. ^(a)Latex paint without fluorinatedcomposition additive

The data in Table 9 demonstrates that Examples 10-12 had improvedcleanability compared to the control. The control consisted of the sameacrylic paint with no composition of the present invention added.

Example 13

To a 3-neck round-bottom flask, equipped with a reflux condenser with anitrogen inlet, a magnetic stirrer, and a temperature probe, was addedcompound C₃F₇OCF₂CF₂CH₂CH₂OH (10.10 g, 30.6 mmol, previously dried oversodium sulfate), and DESMODUR W (63% in MIBK, 5.54 g, 41.9 mmol NCO).The mixture was heated to 55° C., followed by the drop-wise addition ofdibutyl tin dilaurate (1.07 g of a 0.4 wt % solution in MIBK) resultingin an exotherm. The reaction was held at 84° C. for 2 h, followed bydrop-wise addition of MIBK (15.42 g) and water (0.10 g) and continuedheating at 84° C. overnight. Second portion of water (0.10 g) was addedand the reaction was stirred until isocyanate was no longer detected,using an isocyanate test strip. The hot product (5 g) was added to a hotsurfactant solution (70° C., 5 g deionized water, 0.41 g Witco C6094surfactant). The solution was homogenized using a digital sonifier for 5minutes and MIBK was removed via vacuum distillation to provide anaqueous dispersion of urethane polymer (13) for carpet application (12%solids, 3.47% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1, for oil repellency by Test Method 2. Soiling performance of thecarpets was evaluated by Test Method 3 accelerated soiling test andevaluated by the color measurement of soiling performance. Results arelisted in Tables 10 and 11.

Example 14

Another sample was prepared using the method described for example 13,except that the hot product (5 g) was added to a hot surfactant solution((70° C., 5 g deionized water, 0.08 g of MERPOL SE surfactant, from E.I.DuPont de Nemours, Wilmington, Del., and 0.37 g ARQUAD 16-50 surfactant,Akzo Nobel, Chicago). The solution was homogenized using a digitalsonifier for 5 minutes and MIBK was removed via vacuum distillation toprovide an aqueous dispersion of urethane polymer (14) for carpetapplication (12% solids, 4.5% F).

The dispersion was applied to carpet as described above under“Materials”. The carpets were tested for water repellency by Test Method1, for oil repellency by Test Method 2. Soiling performance of thecarpets was evaluated by Test Method 3 accelerated soiling test andevaluated by the color measurement of soiling performance. Results arelisted in Tables 10 and 11.

TABLE 10 Commercial Carpet Example Final ppm F Water Repellency OilRepellency Delta E Untreated 0 0 0 50.29 1A 600 4 3 48.51

TABLE 11 Residential Carpet Example Final ppm F Water Repellency OilRepellency Delta E Untreated 0 0 0 29.13 1B 400 6 5 26.85 ppm F ismicrograms per gram of fluorine

The data in Tables 10 and 11 demonstrates that the polymers of thepresent invention made using a cyclic isocyanate provide excellent

water repellency, oil repellency and soil resistance to carpet.

1. A method of providing water repellency, oil repellency, stainrelease, hydrophilicity stain release, and cleanability to a substratecomprising contacting said substrate with a polymer containing at leastone urea linkage prepared by (i) reacting (1) at least one organicdiioscyanate, polyisocyanate, or mixture thereof, and (2) at least onefluorochemical compound of Formula IR_(f)—O(CF₂CF₂)_(r)(CH₂CH₂)_(q)(R¹)_(s)XH  Formula I  wherein R_(f) is alinear or branched C₁ to C₇ perfluoroalkyl optionally interrupted by oneor three oxygen atoms, r is 1 to 3, q is 1 to 3, s is 0 or 1, X is O, S,or NR² wherein R² is H, or C₁ to C₆ alkyl, and R¹ is the divalentradical selected from —S(CH₂)_(n)—,

p is 1 to 50, and R³, R⁴ and R⁵ are each independently H or C₁ to C₆alkyl; (ii) and then reacting with (3) water, a linking agent, or amixture thereof.
 2. The method of claim 1 wherein the polymer iscontacted with the substrate by means of exhaustion, spray, foam,flex-nip, nip, pad, kiss-roll, beck, skein, winch, liquid injection,overflow flood, brush, roll, spray or immersion.
 3. The method of claim1 wherein for cleanability the polymer is contacted with the substrateas an additive in a coating composition.
 4. The method of claim 1wherein the polymer is contacted with the substrate in the presence ofA) an agent providing at least one surface effect selected from thegroup consisting of no iron, easy to iron, shrinkage control, wrinklefree, permanent press, moisture control, softness, strength, anti-slip,anti-static, anti-snag, anti-pill, stain repellency, stain release, soilrepellency, soil release, water repellency, oil repellency, odorcontrol, antimicrobial, and sun protection, or B) a surfactant, pHadjuster, cross linker, wetting agent, blocked isocyanate, wax extender,or hydrocarbon extender, or C) a mixture thereof.